Method for determining film thickness, method for producing a film and device for producing a film - Patents.com

Abstract

This specification discloses a method for determining the thickness of a wet film, particularly microfibrillated cellulose. The method includes conveying a wet film (20) on a conveyor (10) having a conveyor width, the wet film (20) having a wet film width smaller than the conveyor width, providing a laser projection (1511) across an edge of the film, acquiring a series of images each depicting an area of ​​the conveyor, where the laser projection, a portion of the film, and a portion of the exposed conveyor surface are visible, and using at least some of the images to determine at least one of the film thickness and the film thickness distribution across the film width. This specification also discloses a method for forming a film, particularly a microfibrillated cellulose film, and an apparatus for producing such a film.

Description

[Technical field]

[0001] The present disclosure relates to a method for determining film thickness. The present disclosure also relates to a method and apparatus for producing a film. The method finds particular application in the production of microfibrillated cellulose films. [Background technology]

[0002] Microfibrillated cellulose ("MFC"), or "nanocellulose," is a material composed of cellulose microfibrils that can be separated from the cellulose fiber wall.

[0003] Nanocellulose comprises partially or entirely fibrillated cellulose or lignocellulose fibers. The diameter of the liberated fibrils is less than 1000 nm, while the actual fibril diameter or size distribution and / or aspect ratio (length / width) depends on the source and production method. The smallest fibrils are called elementary fibrils and may have a diameter of about 2-4 nm, but generally, an assembly of elementary fibrils (also defined as microfibrils) is the main product obtained when producing MFCs, for example, using the extended purification process or the pressure drop cracking process. Depending on the source and production process, the length of the fibrils can vary from about 1 to more than 10 micrometers. Coarse nanocellulose grades may contain a significant fraction of fibrillated fibers, i.e. fibrils protruding from the tracheids (cellulose fibers), together with some amount of fibrils liberated from the tracheids (cellulose fibers).

[0004] Nanocellulose can also be characterized by various physical or physicochemical properties such as its large surface area and its ability to form a gel-like material at low solids content (1-5 wt%) when dispersed in water. Preferably, the cellulose fibers are such that the final specific surface area of ​​the formed nanocellulose is between about 1 and about 500 m, as determined by the BET method on solvent-exchanged and freeze-dried material. 2 / g, for example, about 1 to about 200 m 2 / g, more preferably 50 to 200m 2 / g.

[0005] There are various methods to produce nanocellulose, such as single-pass or multi-pass purification, pre-hydrolysis or enzymatic treatment followed by purification or high shear degradation or liberation of fibrils. Nanocellulose can be produced from wood cellulose fibers, both hardwood and softwood fibers. It can also be produced from microbial sources, agricultural fibers, such as straw pulp, bamboo, bagasse, or other non-wood fiber sources. It is preferably produced from pulp, including pulp from virgin fibers, such as mechanical, chemical and / or thermomechanical pulp. It can also be produced from shredded or recycled paper. The term nanocellulose includes parenchymal nanocellulose and BNC (bacterial nanocellulose). Nanocellulose can also be obtained from plant fibers, such as sugar beet or potato-based nanocellulose.

[0006] The above definition of nanocellulose includes, but is not limited to, the definition of nanocellulose in the ISO / TS 20477:2017 standard.

[0007] Further synonyms for nanocellulose / MFC include cellulose microfibrils, fibrillated cellulose, nanofibrillated cellulose (NFC), fibril aggregates, nanoscale cellulose fibrils, cellulose nanofibers, cellulose nanofibrils, nanocrystalline cellulose, cellulose microfibers, cellulose fibrils, cellulose nanofilaments, microfibril cellulose, microfibril aggregates, and cellulose microfibril aggregates.

[0008] Current research indicates that MFC may be a suitable material for packaging and packaging coatings due to its strength and barrier properties, and therefore has the potential to replace or complement currently used barrier films, including polymeric and metallic films.

[0009] Formation of MFC films can be achieved by solution casting of a viscous or gel-like fluid material onto a continuous conveyor belt, followed by dehydration / drying (e.g., evaporation) of the solvent.

[0010] The term "solvent casting" is a known term that refers to a method of producing a film by applying a wet film that includes film-forming ingredients distributed in a medium that is essentially removed, for example, by dehydration and / or evaporation. The film-forming ingredients may be dispersed in a carrier medium or dissolved in a solvent, hence the term "solvent casting."

[0011] However, to achieve uniform film properties and to achieve a film with attractive visual properties, it is important to control the film thickness with high precision and to be able to quickly adjust the film thickness if deviations occur.

[0012] Prior art methods for determining MFC film thickness are limited in that the film must be separated from the substrate or the substrate onto which the film is cast must be transparent, unlike when the film is cast onto a solid steel belt.

[0013] For example, one method used to measure the thickness of continuously cast or extruded films, papers and coatings relies on the absorption of radiation in the web passing between traversing measurement gauges. The problem with such systems is that they cannot be used for MFC films on solid steel belts. Thus, such systems are used for films or webs after separation from the casting or forming substrate, which is problematic for MFC films because MFC films essentially cannot be separated from the substrate until they are dry. Furthermore, the open draw of unsupported films can be detrimental to product quality.

[0014] Another drawback of the above mentioned methods is related to process control: when thickness measurements are used to control the casting process, the delay time between the casting point and the state of the film becomes a drawback. Moreover, traverse measurements only give periodic information from each position in the cross machine direction, which does not capture all process variations.

[0015] Therefore, there is a need for improved methods for determining and controlling film thickness. Summary of the Invention

[0016] A general object of the present disclosure is to provide an improved method and apparatus for determining the thickness of a wet film, which may be a nanocellulose or other cellulose film, and in particular to provide a method and apparatus that allows for more accurate monitoring of the film thickness, and optionally, damage to the film.

[0017] The invention is defined by the accompanying independent claims, and embodiments are set out in the dependent claims, the following description and the accompanying drawings.

[0018] According to a first aspect, there is provided a method of determining a wet film thickness, the method comprising: conveying a film in a wet state on a conveyor having a conveyor width, the wet film having a wet film width less than the conveyor width, providing a laser projection across the conveyor, the laser projection extending over an edge of the wet film, acquiring a series of images, each depicting a region of the conveyor, where the laser projection, a portion of the wet film, and a portion of the exposed conveyor surface are visible, and using at least some of the images to determine at least one of a wet film thickness and a wet film thickness distribution across the wet film width.

[0019] The method allows for real-time tracking and adjustment of film thickness and casting profile. Optionally, film sections can be delivered along with film thickness and / or profile data.

[0020] The method is useful for wet films having a thickness of 10 to 10000 microns, preferably 10 to 5000 microns, 10 to 1000 microns, 50 to 10000 microns, 50 to 5000 microns, 50 to 1500 microns, 50 to 1000 microns or 50 to 500 microns.

[0021] The method is useful for wet films that have less than 80% light transmission at the wavelength of the laser, preferably less than 70%.

[0022] The method is particularly suitable for measuring continuous thickness variations, i.e. thickness variations which extend continuously along the direction of travel of the conveyor.

[0023] In the context of the present application, a wet film is a film having a solids content of less than 50% by weight, preferably 1-50%, 3-50%, 3-20%, 3-15% or 3-6% by weight.

[0024] The wet film is applied as a continuous layer over a substantial portion of the conveyor width and along the direction of conveyor movement.

[0025] It is possible to apply one or more pre-drying or dehydration steps upstream of the area where the image is captured.

[0026] For example, the pre-drying step may include forced evaporation, which may be accomplished by irradiation, for example in the form of IR and / or microwave, to reach a particular desired solids content.

[0027] As another example, a dewatering process may be applied, such as press dewatering or dewatering by capillary effect through a porous matrix, driven by gravity or assisted by vacuum.

[0028] Dehydration and / or subsequent drying can be assisted by irradiation (IR, microwave), steam or hot air impingement.

[0029] The laser projection can be a line or any predetermined pattern.

[0030] For example, the laser projection may extend across a width greater than the wet film width.

[0031] A wet film comprises film-forming components that are distributed in a medium that is essentially removed by a separation method such as dehydration and / or evaporation to arrive at a dry film. In the context of this application, a dry film is a film having a medium content of 0.1 to 15 wt. %.

[0032] The film-forming ingredients can be dispersed in the carrier fluid, whereby the carrier fluid is essentially removed, or the film-forming ingredients can be dissolved in the solvent, whereby the solvent is essentially removed, in either case the medium is in the liquid stage when casting occurs.

[0033] The film-forming component may include MFC and one or more property-improving additives and / or fillers. Preferably, the film-forming component includes at least 50% by weight MFC, preferably at least 60%, at least 70% or at least 80% MFC. For example, the film-forming component may also include other natural fiber materials in addition to MFC.

[0034] The film-forming component also optionally comprises a water-soluble polymer capable of forming a film and / or improving the bonds between the cellulose fibrils. Typical examples of such polymers are e.g. natural gums or polysaccharides or their derivatives, e.g. CMC, starch.

[0035] The film may comprise film-forming components distributed in a medium that is essentially removed, where the medium content of the wet film at the time of image capture is at least 75% by weight, preferably greater than 80%, greater than 85%, greater than 90%, or greater than 95% by weight.

[0036] The film may be a cellulose-based film, in particular a microfibrillated cellulose (hereinafter "MFC") film.

[0037] The MFC may be an unmodified MFC or a chemically modified MFC, or a mixture thereof. An unmodified MFC refers to an MFC made from unmodified or native cellulose fibers. An unmodified MFC may be a single type of MFC or may include a mixture of two or more types of MFC, differing, for example, in the choice of cellulose raw material or the method of production. A chemically modified MFC refers to an MFC made from cellulose fibers that have been chemically modified before, during, or after fibrillation. A chemically modified MFC may be a single type of chemically modified MFC or may include a mixture of two or more types of chemically modified MFC, differing, for example, in the type of chemical modification, the choice of cellulose raw material, or the method of production.

[0038] The laser projection may be applied between the casting device and the first drying device, preferably closer to the casting device than the drying device.

[0039] That is, the laser projection is applied to the wet film while the film is still in a wet state.

[0040] The laser projection may be applied at a location along the forward direction of the conveyor where the belt support is located.

[0041] Thus, the laser projection is applied to a portion of the belt that exhibits relatively small vertical variations due to the belt support.

[0042] The conveyor may be a metal belt conveyor, such as a steel belt conveyor, a polymer conveyor, or a paper conveyor.

[0043] The conveyor may extend laterally beyond the edges of the wet film on either lateral side of the wet film.

[0044] The laser projection may be applied as a fixed pattern, or the laser may be scanned at a frequency greater than the image capture frequency to effectively present the pattern.

[0045] The laser projection may be applied in a vertical plane including the conveyor's travel direction, with the laser direction extending at an angle to said travel direction, said angle being between 5 and 80 degrees, preferably between 10 and 60 degrees or between 15 and 40 degrees.

[0046] Alternatively, the laser projection may be applied in a vertical plane including the conveyor travel direction, with the laser direction extending at an angle to said travel direction, said angle being between 100 and 175 degrees, preferably between 100 and 150 degrees or between 105 and 130 degrees.

[0047] The image may be captured such that the image plane of the image capture device is perpendicular to a line extending in the vertical plane and at an angle of 30 to 150 degrees, preferably 40 to 90 degrees, to the laser direction.

[0048] The laser direction and the line normal to the image plane are coplanar and may be perpendicular and parallel to the conveyor travel direction.

[0049] The wet film thickness may be determined as the difference between the measured distance to the conveyor surface laterally outside the wet film and the measured distance to the wet film surface.

[0050] The average wet film thickness may be determined as the difference between a measured distance to the conveyor surface laterally outside the wet film and multiple measured distances to the wet film surface within the wet film width.

[0051] According to a second aspect, there is provided a method of producing a film, comprising providing a continuous conveyor having a conveyor width, using a casting apparatus for applying a film onto the conveyor, the film comprising film-forming ingredients distributed in a medium that is essentially removed to solvent cast the film, determining a wet film thickness and / or wet film thickness distribution according to the method described above, and adjusting at least one casting parameter based on the determined wet film thickness and / or wet film thickness distribution to vary the wet film thickness and / or wet film thickness distribution provided by the casting apparatus.

[0052] Casting equipment suitable for applying liquid to a continuous conveyor belt is known as such and typically includes an elongated nozzle extending along the width direction and having a length corresponding to the width of the film layer to be formed.

[0053] After image capture, the film passes through one or more dehydration and / or drying zones where the wet film medium is removed to yield a dry film.

[0054] Films formed by this method may have a thickness, when dry, of from 10 to 100 microns, preferably from 15 to 60 microns.

[0055] The film can be a barrier film, a membrane film, or a nanopaper.

[0056] Adjusting the at least one casting parameter may include adjusting a feed rate and / or a feed distribution of the film.

[0057] Adjusting at least one casting parameter can include adjusting a doctor blade configured to control the wet film thickness and / or the wet film thickness distribution.

[0058] Adjusting at least one casting parameter can include adjusting a lip of a slot die casting unit.

[0059] According to a third aspect, there is provided an apparatus for producing a film comprising: a continuous conveyor having a conveyor width; a casting apparatus for applying a wet film onto the conveyor, the casting apparatus comprising film-forming components distributed in a medium to be essentially removed, the casting apparatus for solution casting the film to provide a wet film width smaller than the conveyor width; a laser projection apparatus configured to provide a laser projection across an edge of the wet film; an image capture apparatus configured to acquire a series of images, each depicting an area of ​​the conveyor, where the laser projection, a portion of the wet film, and a portion of the exposed conveyor surface are visible; and a processing apparatus configured to use at least some of the images to determine at least one of a wet film thickness and a wet film thickness distribution across the wet film width.

[0060] The apparatus may further include an adjustment device configured to adjust the casting apparatus based on the determined film thickness and / or film thickness distribution to alter the film thickness and / or film thickness distribution provided by the casting apparatus. [Brief description of the drawings]

[0061] [Figure 1] FIG. 1 is a schematic side view of an apparatus for solution casting of a film. [Diagram 2] FIG. 2 is a schematic top view of the device of FIG. 1. [Diagram 3] FIG. 3 shows a schematic top view of a detail of the device of FIG. 2. [Figure 4] FIG. 2 is a diagram showing a schematic diagram of the laser projection device of FIG. 1 in detail. [Diagram 5] 1 is a graph showing wet film thickness across the width of the film. [Figure 6] 1 is a graph showing the change in average wet film thickness over time. [Figure 7] 1 is a graph showing dry film thickness measured at points spaced 1 cm apart in the cross film direction Y. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0062] The drawings show diagrammatically apparatus in which the invention can be implemented. Apparatus for use in belt casting is known as such and will therefore only be briefly described with reference to the drawings.

[0063] The belt casting apparatus typically includes a conveyor belt 10, which may be a solid steel belt or a continuous smooth belt of polymeric or paper material.

[0064] The steel belt may be ground or polished to provide a smooth film surface. For a very smooth film surface, a mirror quality polished steel belt may be used.

[0065] The polymeric or paper belt may have a surface coating to make the surface sufficiently smooth.

[0066] The conveyor belt may be a continuous or endless conveyor belt, such as a metal belt, in particular a steel belt.

[0067] The conveyor belt is arranged to run over at least a pair of conveyor belt pulleys 11, 12, at least one of which may be a drive pulley. Further support pulleys may be provided, but need not be. Typically the belt speed may be of the order of at least 10 m / min, possibly at least 50 m / min or at least 75 m / min.

[0068] The belt width may be of the order of 0.3 to 8 m, typically 0.5 to 6 m or 1 to 5 m.

[0069] A drying chamber 13 may be provided over a portion of the belt. Such a drying chamber may be arranged to completely surround the belt when viewed in cross section perpendicular to the direction of belt travel. The drying chamber may include one or more zones in which controlled temperature, gas atmosphere and air flow may be provided. For example, it may be desirable to provide high temperatures to promote evaporation of the solvent and low humidity air to maximize the air's ability to receive the evaporated solvent. The exhaust air stream may be connected to a solvent recovery or destruction device.

[0070] The drying chamber may be preceded by one or more pre-drying or dewatering zones (not shown).

[0071] One or more pre-drying or dehydration steps may be provided upstream of the area where the image is captured.

[0072] Alternatively, or as a complement, one or more pre-drying or dehydration steps may be provided downstream of the area where the images are captured and upstream of drying chamber 13 .

[0073] For example, the pre-drying step may include forced evaporation, which may be accomplished by irradiation, for example in the form of IR and / or microwave, to reach a particular desired solids content.

[0074] In another example, a dewatering step may be applied, such as press dewatering or dewatering by capillary effect through a porous matrix, gravity driven or vacuum assisted.

[0075] Dehydration and / or subsequent drying can also be assisted by irradiation (IR, microwave), steam or hot air impingement.

[0076] At one end of the conveyor 10, such as by a first belt pulley 11, a film applicator 14 may be provided. The film applicator 14 may have one or more feeders 141 and / or doctor blades 142, which can be used to control the film thickness and / or thickness distribution across the belt width.

[0077] The controller 15 may be arranged to control the feeder 141, an external feed pump (not shown), the lip and / or doctor blade 142 of the slot die casting unit via drive motors or actuators (not shown).

[0078] The laser projection device 15 comprises a laser source 151 and an image capture device 152, for example a camera.

[0079] A laser projection device 151 provides a laser projection 1511 across the width of the film, and an image capture device 152 acquires an image of at least a portion of the laser projection 1511 .

[0080] On a flat surface, the laser projection 1511 will provide a predetermined pattern, such as, but not limited to, a straight line extending across the conveyor 10 perpendicular to its direction of travel.

[0081] The laser may operate at a wavelength of about 380-900 nm, preferably 380-750 nm, more preferably 625-740 nm.

[0082] The laser projection device 151 may be formed with one or more laser sources 151, which may be adjusted to provide different portions of the laser projection 1511 and / or to reinforce each other to provide increased intensity of the projection 1511.

[0083] Laser projection devices can operate by scanning a laser dot or with a fanning filter to provide a stationary projection.

[0084] In use, the conveyor belt is driven at a predetermined speed in a forward direction, shown in the drawings as the "X" direction, while film solution 20 is dispensed onto the belt surface. In an area downstream of the film applicator, a laser projection 1511 is applied to the entire film while an image capture device 152 is used to acquire respective images showing the laser projection, the film surface, and the exposed belt surface laterally outward of the film surface.

[0085] 4, the laser source 151 may be directed along a direction D151 at an angle a of 5-80 degrees, preferably 10-60 degrees, or 15-40 degrees, relative to the conveyor surface, as viewed in a vertical plane XZ parallel to the conveyor travel direction. As specific examples, the laser source may be directed at an angle of 10-20 degrees, 20-30 degrees, 30-40 degrees, 40-50 degrees, 50-60 degrees, 60-70 degrees, or 70-80 degrees relative to the conveyor surface.

[0086] Alternatively, if the laser projection is along a direction opposite to the forward direction, the angle may be 100-175 degrees, preferably 100-150 degrees or 105-130 degrees.

[0087] The image capture device 152 may be oriented along a direction D152 at an angle b between 30 and 150 degrees, preferably between 40 and 90 degrees, relative to the laser source direction D151, as viewed in said vertical plane XZ.

[0088] A filter 153 may be placed in the path of the laser light between the conveyor and the image capture device 152. The filter may be tuned to the laser wavelength of interest.

[0089] The film thickness direction is shown as the "Z" direction in the drawings, and the film width direction is shown as the "Y" direction in the drawings.

[0090] The controller 15 receives the images and performs image processing to determine the film thickness and / or film thickness distribution across the film width.

[0091] Based on the determined film thickness and / or film thickness distribution, if the controller 15 determines that the film thickness and / or film thickness distribution is outside of an acceptable range, the feeder 141, an external feed pump (not shown), the lip and / or the doctor blade 142 of the slot die casting unit may be adjusted to adjust the film thickness.

[0092] If the film is applied wet it may have 1-25% or 3-20% by weight solids, the remaining portion being solvent(s) or dispersion medium(s), preferably the solids portion being 1-3%, 3-6%, 6-9%, 9-12%, 12-15%, 15-18%, 18-21%, 21-24% or 24-25% (by weight).

[0093] The solids portion may comprise a main ingredient, such as an MFC, and one or more additives. The main ingredient may be present at least 50% by weight of the solids portion, preferably at least 60, 70, 80 or 90% by weight.

[0094] Typical additives used to provide particular film properties may include antiblocking and antistatic compounds, chelating agents, colors, conductive materials, pigments, and the like.

[0095] Other additives may include natural fibrous materials, such as wood-based materials.

[0096] The film passes through a drying chamber and is then stripped off of belt 10 after which it may be packaged for shipping, such as by being wound onto reel 16.

[0097] The conveyor belt may be supported by one or more belt supports 17, which may be provided as roller or sliding supports, and which may extend across all or part of the belt width.

[0098] The laser projections may be applied to the belt surface at the contact between the support 17 and the belt 10. Preferably, the laser projections may be located within an X-direction distance of 50% of the support roller diameter from a contact line parallel to the Y-axis between the support roller 17 and the belt 10, preferably within a distance of 25% of such support roller diameter.

[0099] FIG. 3 is an enlarged schematic diagram of a section of belt 10 with wet film 20, with an example image frame 30 shown in dashed lines and laser projection 1511 shown in broken lines.

[0100] Preferably, the laser projection is provided in a vertical plane parallel to the forward direction X of the conveyor belt, i.e. in the XZ plane, with the laser direction at angle a as described above.

[0101] In the illustrated case, the laser projection 1511 on the target area represents five slices offset relative to one another in the X direction, thus indicating the thickness and / or thickness variation of the film 20 .

[0102] A first pair of laser projections 15111, 15115 hit the exposed surface portion 101 of the belt 10. These laser projections 15111, 15115 therefore indicate a zero thickness level and can be used to indicate a reference plane parallel to the XY plane.

[0103] A second pair of laser projections 15112, 15114 strikes the surface of the wet film 20 and is closer to the projection device 141 than the first pair of laser projections, indicating a higher level, which may be the desired film surface.

[0104] The third laser projection portion 15113 extends laterally beyond the second pair of laser projection portions 15112, 15114 and therefore indicates a lower level.

[0105] Thus, the distance in the X direction between the first and second pair of laser projections 15111, 15115; 15112, 15114 indicates the film thickness. Knowing the projection angle and said distance in the X direction, the film thickness can be calculated.

[0106] A third laser portion 15113 exhibiting a reduction in thickness can be similarly identified and measured.

[0107] Images may be taken at a predetermined frequency, which may be determined based on the speed of the belt.

[0108] Each image can be analyzed to identify the location of the laser projection in the image and calculate, for example, the average film thickness, the maximum film thickness, the minimum film thickness, or the film thickness standard deviation.

[0109] If one or more of the above mentioned parameters fall outside of a predetermined range, an alarm may be activated and the feed and / or conveyor advancement may be stopped.

[0110] The results may be used as input to adjust the feeder 14. Such adjustments may include adjusting the feed rate across all or a portion of the width of the feeder 141.

[0111] Optionally or as a complement, the results can be used as input for adjusting the doctor blade 142 .

[0112] Further optionally or as a complement, the results can be used as input to adjust the lip of a slot die casting unit.

[0113] Further optionally, the produced film may be provided with an animation detailing the thickness profile for the entire film or for a portion of the film.

[0114] Although the disclosure herein has been directed to MFCs, it will be understood that the methods and apparatus may also be used in the production of other types of films, including, but not limited to, cellulose-based films, such as cellulose triacetate, polymeric films, such as polyimides, liquid crystal polymers or poly(vinylidene fluoride), and edible films, such as sodium caseinate and calcium caseinate based films.

[0115] To achieve an accurate measurement of the film, it is possible to measure the film thickness at the additional belt support, as previously described.

[0116] As an additional measure, it is possible to carry out a calibration run on the belt, thereby determining the shape of the belt when it is empty of film.

[0117] Such laser measurements can also be made simultaneously on the underside of the belt and used to correct for variations in belt shape and / or motion. EXAMPLES

[0118] Below we present the data from the test runs.

[0119] A film comprising microfibrillated cellulose was produced in a belt casting machine consisting of a film applicator 14, a feeder 141, a doctor blade 142, and a carrier medium or conveyor 10 in the form of a steel belt having an Ra roughness of 1.3 μm and an Rz roughness of 7.5 μm.

[0120] The suspension was spread on a conveyor 10 to form a wet film 775 μm thick and 500 mm wide at a speed of 5.5 m / min (speed of the steel belt). The solids content of the wet film was 4.21% by weight, i.e. 95.79% by weight of water, 3.58% by weight of microfibrillated cellulose and 0.63% by weight of sorbitol.

[0121] The microfibrillated cellulose used was enzyme-treated bleached kraft fiber, which was further degraded and high pressure fluidized to obtain a fine MFC quality that was essentially free of fiber residues.

[0122] The thickness of the wet film 20 was measured with a laser projection device 15 after deposition to obtain the wet film and before further dehydration or evaporation / drying 13 .

[0123] A 660 nm wavelength laser source 151 was used to generate a cross-machine direction laser line across the width of the wet film on the steel belt substrate, extending approximately 10 cm outward from the edge of the wet film.

[0124] The position of the laser line was approximately 50 cm downstream of the deposition of the wet film in the direction of movement X of the steel belt. The laser line was projected onto the wet film from a laser direction D151 extending at an angle of 130 degrees to the direction of movement X of the steel belt. A camera was used as the image capture device 152 to acquire images of an area of ​​the moving steel belt where the laser projection, a portion of the wet film and a portion of the steel belt were visible. The images were captured at a frame rate of 30 frames per second. The camera was positioned at an angle D152 of 60 degrees from the direction of the laser and 70 degrees to the direction of movement X of the steel belt.

[0125] Each image was analyzed for the location of the laser line on the wet film or on the steel belt, and therefore specific camera pixels were assigned to correspond to specific height positions of the wet film and steel belt. Film thickness was obtained from this data by subtracting the height position of the steel belt from the height position of the wet film at each cross-machine Y position. The film thickness data from each cross-machine position was then placed on a thickness-CD-position diagram to obtain the film thickness profile as shown in Figure 5.

[0126] Additionally, various statistics could be calculated from the data, such as the average thickness and the standard deviation of the average thickness. The average thickness was measured to be 775 μm with a standard deviation of 22 μm. The data could be further stored and plotted against time, allowing the evolution of the average thickness and its standard deviation over time to be tracked, as shown in Figure 6.

[0127] The corresponding dry film thicknesses are illustrated in FIG. 7, where the dry film thicknesses were measured at points spaced 1 cm apart in the cross-film direction Y.

Claims

1. 1. A method for determining wet film thickness comprising the steps of: conveying the wet film (20) in a wet state on a conveyor (10) having a conveyor width, the wet film (20) having a wet film width smaller than the conveyor width; providing a laser projection (1511) across the conveyor (10), the laser projection extending over an edge of the wet film; acquiring a series of images, each depicting an area of ​​the conveyor, where the laser projection, a portion of the wet film, and a portion of the exposed conveyor surface are visible; and determining at least one of a wet film thickness and a wet film thickness distribution across a wet film width using at least a portion of the image; 16. A method for determining wet film thickness comprising:

2. The method of claim 1 , wherein the laser projection extends across a width greater than the width of the wet film (20).

3. 3. The method of claim 1 or 2, wherein the wet film (20) comprises film-forming components distributed essentially in the medium to be removed, the wet film having a medium content of at least 75% by weight.

4. The method of claim 1 or 2, wherein the wet film (20) is a cellulose-based film.

5. 3. The method according to claim 1 or 2, wherein the laser projection is applied between the casting device (14) and the first drying device (13) and closer to the casting device (14) than to the drying device (13).

6. 3. The method according to claim 1 or 2, wherein the laser projection (1511) is applied at a position along the forward direction (X) of the conveyor where the belt support (17) is located.

7. The method according to claim 1 or 2, wherein the conveyor (10) is selected from a metal belt conveyor, a polymer conveyor, or a paper conveyor.

8. 3. The method according to claim 1 or 2, wherein the conveyor (10) extends laterally beyond the edges of the wet film (20) on both lateral sides of the wet film.

9. 3. The method of claim 1 or 2, wherein the laser projection (1511) is applied as a fixed pattern or the laser is scanned at a frequency greater than the image capture frequency to effectively present the pattern.

10. 3. The method according to claim 1 or 2, wherein the laser projection (1511) is applied in a vertical plane including the conveyor's direction of travel (X) from a laser direction (D151) that extends at an angle to said direction of travel, said angle being between 5 and 80 degrees.

11. 3. The method according to claim 1 or 2, wherein the laser projection (1511) is applied in a vertical plane including the conveyor's direction of travel (X) from a laser direction (D151) that extends at an angle to said direction of travel, said angle being between 100 and 175 degrees.

12. The method of claim 10, wherein the image is captured such that the image plane of the image capture device is perpendicular to a line extending in the vertical plane and is between 30 and 150 degrees to the laser direction.

13. 3. The method of claim 1 or 2, wherein the wet film thickness is determined as the difference between the measured distance to the conveyor surface laterally outside the wet film and the measured distance to the wet film surface.

14. 3. The method of claim 1 or 2, wherein the average wet film thickness is determined as the difference between a measured distance to a conveyor surface laterally outside the wet film and a plurality of measured distances to the wet film surface within the wet film width.

15. 1. A method of making a film, comprising the steps of: Providing a continuous conveyor (10) having a conveyor width; using a casting apparatus (14) for applying a film (20) onto a conveyor, the film (20) including film-forming ingredients distributed in a medium that is essentially removed to solvent cast the film; Determining the wet film thickness and / or the wet film thickness distribution according to the method of any one of claims 1 to 14, and adjusting at least one casting parameter based on the determined wet film thickness and / or wet film thickness distribution to vary the wet film thickness and / or wet film thickness distribution provided by the casting device. A method for producing a film comprising:

16. The method of claim 15 , wherein adjusting at least one casting parameter comprises adjusting a wet film feed rate and / or feed distribution.

17. 17. The method of claim 15 or 16, wherein adjusting at least one casting parameter comprises adjusting a doctor blade (142) configured to control wet film thickness and / or wet film thickness distribution.

18. 17. The method of claim 15 or 16, wherein adjusting at least one casting parameter comprises adjusting a lip of a slot die casting unit.

19. 1. An apparatus for producing a film, comprising: A continuous conveyor (10) having a conveyor width; a casting device (14) for applying a wet film onto a conveyor, the wet film comprising film-forming ingredients distributed in a medium that is essentially removed for solution casting the film to provide a wet film width that is smaller than the conveyor width; a laser projection device (151) configured to provide laser projection over an edge of the wet film; an image capture device (152) configured to capture a series of images, each depicting an area of ​​the conveyor, where the laser projection, a portion of the wet film, and a portion of the exposed conveyor surface are visible; and a processor configured to determine at least one of a wet film thickness and a wet film thickness distribution across a wet film width using at least a portion of the image; An apparatus for producing a film comprising:

20. 20. The apparatus of claim 19, further comprising an adjusting device (141, 142) configured to adjust the casting device based on the determined wet film thickness and / or wet film thickness distribution to vary the wet film thickness and / or wet film thickness distribution provided by the casting device.

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